AluGrid The flat roof system with optimized superimposed load quick, simple and mainly tool-free mounting reduced number of components economically effi cient system structural analysis based on the latest research on wind dynamics On many fl at roofs, the area that can be used for photovoltaic installations can be enlarged by using loadoptimized systems. Besides the systems that have been proven for years like CompactVario, SolRack, Windsafe, SolTube, etc., the AluLight system is a further system that can be used for the fastening of modules on fl at roofs with minimum superimposed loads in completely closed rows and a fi xed elevation angle of 10 or degrees. AluGrid can only be used if the snow loads do not exceed 2.4 kn/m². The components are connected using our well-proven Klick-system. The mounting of the modules to the substructure is carried out using screw-less module clamps (spring clamps). The loading can be optimized (reduced) individually according to the to the structural requirements and be put into the tubs that are attached to the rear wall. By using approved aluminum materials, both a virtually unlimited duration even with high UV-irradiations and certain acceptance in structural expertises is safeguarded. Loading: Concrete stones (for example curb stones, paving stones), gravel, etc. A special structural analysis regarding the superimposed load has to be carried out in order to determine the required loading. This structural analysis is available on our website or in combination with a shade distance calculation and the row distances that have to be maintained within the framework of an offer calculation. 1 / 7
Module clamping: Module spring clamps are available for module heights from 30-51. Depending on the module sizes, there is a range of Windsafe metal sheets that can be chosen from for all module sizes that are available on the market. The modules are clamped in the edge areas of the longitudinal sides. The customer has to check whether the clamping area determined by the module producer is maintained. A pair of special pliers is required for the mounting of the modules. Please fi nd more information about this matter in the AluGrid mounting instruction. Support rubber: We recommend to install the support rubber (6 mm rolled material 166003-001) as a building protection element between the AluGrid continuous beam and the roof cladding of the fl at roof. We recommend to lay the rubber without interruptions. The rubber can be attached to the profi les. A drainage system on the roof has to be provided, too. The ideal fl ow direction is parallel to the continuous beams. If the fl ow direction is not parallel, the rubber can be interrupted. We recommend a support length of 300 mm and gaps of 100 mm. The openings that are created like that allow a draining off of the water horizontally to the cross beams. The customer has to check, if the quantity of the water that can drain of is suffi cient. The support rubber is made of high-value EPDM material. Damage to the EPDM profi le by touching materials that are usually used on roofs can largely be ruled out. The compatibility with Bitumen roofi ng membranes is excellent and all plastic roofi ng membranes do not harm the EPDM-profi le in any way. For some roofi ng membranes, we have been given the approval for the application of the EPDM-profi le on their roofi ng membranes. As there are so many different roofi ng membranes on the market, it is not possible to verify this for all types of roof membranes. With roof membranes by other manufacturers, the customer has to check the compatibility of material with the manufacturer. A potential incompatibility of materials with PVC roofi ng membrane due to plasticizer migration is a known fact. Compatibility of AluGrid support rubbers with roofing membranes. Manufacturer Product information Material compatibility Alwitra Evalon white conditional approval* Evalon grey conditional approval* Evalon colored conditional approval* Evalastic R grey conditional approval* Bauder Bitumen roof sheetings Thermofol (PVC roof sheeting) Thermoplan (FPO roof sheeting) Termofi n (FPO roof sheeting) FDT Rhenofol compatibility only with additional measures*** Rhepanol HG compatibility only with additional measures*** Soprema Bitumen roof sheetings Hirler VAEplan white VAEplan grey VAEplan colored Polyfi n Polyfi n 1020 bright grey no objections O.C.-Plan 3020 black no objections Sika Sikaplan S15 light gray Sikaplan S15 anthracite Sikaplan SgmA 15 beige Sika Sarnafi l T66-15 D beige * In the course of time, discolorizations and/or other imprints in the roof membrane surface may arise. But according to our long-term practical experience, this does not lead to any deterioration. ** Application is only possible with special safety measures, for example separation layers according to manufacturer s instructions *** Additional measure: Plastic fl eece made of polyester, polypropylen or a combination of both with 180g/qm 2 / 7
Dimensioning: Conveniently with our auto-calculator (Schletter creates a structural analysis regarding the superimposed loads). Layout: The components are delivered to the site as single parts and are assembled on location in just a few simple work steps. System variants AluGrid AluGrid+ (available starting from the fi rst quarter of 2012) AluGrid100 (scheduled for 2012) Basic design of the fl at roof system with optimized (reduced) load. With AluGrid+, extra rails are delivered for the lower module edge that are fastened to the continuous beams using special fastening clamps. Thus, the spring clamps can be fastened both to the upper and the lower module edge at the fastening points determined by the manufacturer. With this special AluGrid design, the modules are aligned in east/west direction as a standard. Thus, virtually the whole roof area can be used for module laying. 3 / 7
System variant AluGrid+ With variable module clamping points With the AluGrid system, maximum economic effi ciency was reached by consistent material reduction. The best and most economic solution is possible with modules that can be clamped at the outer edges and have an accordant approval. In this context it has to be taken into account that there must not always be a general approval for all loading conditions according to IEC 61215. In individual cases, an approval for the respective project can be suffi cient, as the relevant regional wind and snow loads can be considered individually. But if the module cannot be clamped at the outer edges, the AluGrid+ system must be used as an alternative. With AluGrid+, extra rails are delivered for the lower module edge that are fastened to the continuous beams using special fastening clamps. The length of these rail pieces are determined in such a manner that the AluGrid module clamp can be mounted at the fastening spots determined by the manufacturer up to 25% away from the module edge. Moreover, the upper fastening to the Windsafe metal sheet can be carried out at the fastening points specifi ed by the manufacturer. Due to the constructional height of the lower rail, the module inclination is reduced by 1 compared to the basic AluGrid design. With AluGrid+, an optimum system price can be achieved even with modules that do not have a general clamping approval. Determined by the system, this price is slightly higher than the price of the basic AluGrid design. 4 / 7
Component overview Continuous beam 166501-006 Continuous beam 6m 166501-004 Continuous beam 4m 166501-001 Continuous beam customized cut 169005-001 Insertion connector kit Bearing rubber as a protection of the building surface 166003-001 Bearing rubber for continuous beams 6mm rolled material Windsafe metal sheets (rear wall metal sheet) for module inclination of about 15, select the item number from the chart: Module length (mm) Module width (mm) 780-859 940-1019 1020-1100 1300-1360 169007-116* 169007-117 1381-1439 169007-137 1440-1500 169007-146* 169007-147 1501-1559 1560-1620 169007-164* 169007-167 1621-1680 169007-174* 169007-176* 169007-177 1681-1740 169007-186* 1940-2000 169007-236* *in stock for 15 module inclination, all other sizes are produced on request for module inclinations of about 10 (for Italy), select the item number from the chart: Module length (mm) Module width (mm) 780-859 940-1019 1020-1100 1300-1360 169009-116* 169009-117 1381-1439 169009-137 1440-1500 169009-146* 169009-147 1501-1559 1560-1620 169009-164* 169009-167 1621-1680 169009-174* 169009-176* 169009-177 1681-1740 169009-186* 1940-2000 169009-236* *in stock for 10 module inclination, all other sizes are produced on request 5 / 7
End caps for Windsafe metal sheets 169006-001 End cap for Windsafe, module width B780-859 ( B stands for width ) 169006-002 End cap for Windsafe, module width B940-1019 169006-005 End cap for Windsafe, module width B1020-1100 169006-004 End cap for Windsafe 10, module width B780-859 169006-003 End cap for Windsafe 10, module width B940-1019 169006-006 End cap for Windsafe 10, module width B1020-1100 Accessories 166002-001 Fastening clamp 166002-002 Lower module bearing 166002-003 Lower module bearing 10 166004-001 Cable covering clip 1 166502-006 Cable covering 6m 2 } 1 2 AluGrid module clamps 166001-050 Module clamp for module thickness 50/51 mm 166001-048 Module clamp for module thickness 48/49 mm 166001-046 Module clamp for module thickness 46/47 mm 166001-044 Module clamp for module thickness 44/45 mm 166001-042 Module clamp for module thickness 42/43 mm 166001-040 Module clamp for module thickness 40/41 mm 166001-039 Module clamp for module thickness 39 mm 166001-038 Module clamp for module thickness 38 mm 166001-037 Module clamp for module thickness 37 mm 166001-036 Module clamp for module thickness 36 mm 166001-035 Module clamp for module thickness 35 mm 166001-034 Module clamp for module thickness 34 mm 166001-033 Module clamp for module thickness 33 mm 166001-032 Module clamp for module thickness 32 mm 166001-031 Module clamp for module thickness 31 mm 166001-030 Module clamp for module thickness 30 mm AluGrid+ For a fastening according to the specifications by the manufacturer up to 25% away from the module edge Determined by the system, the inclination of the module is about 1 lower than compared to the basic design. 166503-00950 AluGrid FK lower module-bearing profi le 14 degrees 950 mm for module lengths from 1300-1740 mm 166503-01100 AluGrid FK lower module-bearing profi le 14 degrees 1100 mm for module-bearing profi le from 1741-2000 mm 166504-00950 AluGrid FK lower module-bearing profi le 9 degrees 950 mm for module lengths from 1300-1740 mm 166504-01100 AluGrid FK lower module-bearing profi le 9 degrees 1100 mm for module bearing profi les from 1741-2000 mm 166002-004 AluGrid fastening clamp for module-bearing profi le 6 / 7
Potential connection: All connections within the AluGrid system are conductive and designed with cross sections that are suffi cient for an earthing (grounding) according to the accordant technical standards. Thus, the internal potential connection of the rack is fully safeguarded. In contrast to other systems with common middle clamps, the module frame is also conductively integrated into the rack by the utilization of toothed high-grade steel clamps. Thus, there is a complete potential connection within the system. Thus, it is suffi cient for the integration of the rack into the potential equalization to connect the rack at one point with an earth conductor that has a suffi cient cross section and to connect this ground conductor to the main earthing terminal of the building. Lightning ampacity: The lightning protection of a solar plant respectively the building below the solar plant generally has to be planned by the system supplier. The expression lightning ampacity is used for connections, clamps etc. that actively have to deduct lightning current within the framework of a lightning protection system. Each of these components has to be tested and certified within the framework of a special test. The lightning ampacity of a rack system is usually not relevant for this problem, as the load-bearing system is not used as a conductor or as a lightning rod as part of the external lightning protection. The lightning protection usually has to be planned completely independent from the solar plant. Usually, a defi ned separation distance between the solar plant and the lightning protection plant has to be maintained. In certain cases, it is also admissible to connect the rack system to the lightning protection system, but in this case the coupling of partial lightning currents has to be reckoned with. In this case it is relevant that the internal connections of the rack are connected with an accordant low impedance and at the same time with a suffi cient cross section. This is the case with the AluGrid system. Technical data Material Structural analysis Windsafe metal sheet and end cap: AIMg3; continuous beam: Alu ENAW6063; profi le rubber: EPDM; Lower module support 1.4301; Fastening clamps and module clamps: 1.4310; Lower bearing profi le and cable covering: ENAW6063; Fastening clamp module-bearing profi le: 1.4301 Structural analysis in accordance with current national standards (in Germany DIN1055 and EC1). Structural analysis attachment on the dimensioning of the number of the required fastening spots. By all means, observe the structural analysis information. The dimensioning is carried out by the company Schletter, for this purpose, we need a completed check list for an inquiry regarding an elevated PV plant. Further information and declaration of warranty at www.schletter.eu Subject to technical modifi cations. Schletter GmbH, 2012, I400191GB, V8 7 / 7